Method and apparatus for pressure baking including a filling encapsulant system

ABSTRACT

A baked food product is described including a filling surrounded by a baked layer. An edible encapsulant layer surrounds the filling and is disposed between the filling and the baked layer. The encapsulant layer may be formed of a protein encapsulated starch and serves to maintain separation between the filling and the surrounding baked layer during initial baking and during subsequent storage and re-heating, even in cases of a liquid type filling. A baking method is described in which a baking mixture is prepared including at least one leavening agent provided in a predetermined amount. The baking mixture is then baked in a way which limits expansion of the baking mixture to establish a baked density of the baked product and such that the predetermined amount of the leavening agent is sufficient to limit the time required for baking the baked comestible. The predetermined amount of leavening agent may also serve in forming an enhanced thin crust surrounding the baked product. The enhanced thin crust is particularly useful in a baked product including the described encapsulant layer containing a filling, since toaster stable products suited for refrigerable storage are readily produced.

RELATED APPLICATIONS

[0001] This application is a Continuation-In-Part of U.S. applicationSer. No. 09/458,378 filed on Dec. 12, 1999, which is a Divisional ofU.S. application Ser. No. 08/950,984 filed on Oct. 15, 1997.

BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to a method and apparatusfor producing comestibles using pressure baking. The method andapparatus are particularly well suited for producing toaster stablecomestibles which may be frozen or which may be formulated to include anextended shelf life.

[0003] Food products which may be prepared by heating in a toaster havebecome increasingly popular for reasons including convenience and swiftpreparation in a fast paced society. Products which are currentlyproduced and designed for re-heating in a toaster include sliced bread,pancakes, french toast and waffles. Unfortunately, however, most othervariations of baked products are not well suited for re-heating in atoaster. These products include, but are not limited to, cookies,muffins, most cakes and biscuits. Cookies when re-heated in a toasterwill often lose structure, fall apart, and often create a fire hazard.Muffins, though certain types are sliced and toasted, are not designedfor optimum toasting in an upright toaster. Most cakes, with theexception of very heavy cakes like a pound cake, cannot produce slicesthat have appropriate physical integrity. That is, cake slices that arethin enough for upright toasting have a tendency to fall apart in thetoaster. Biscuits, if made thin enough, can be reheated in a toaster,but are not designed for easy removal and/or optimum tastecharacteristics. Moreover, biscuits readily become too dry when preparedin an upright toaster. Also, in an upright toaster, fillings andcoatings can be problematic, particularly if they come in contact withthe heating grid surface.

[0004] In an attempt to provide a broader base of baked goods suitablefor re-heating in a toaster, shelf stable and frozen toaster pastrieshave been developed. Shelf stable toaster pastries include a lowmoisture pastry surrounding a relatively small amount of low moisturefilling. Toppings have been designed for shelf stable pastries that arebased on very low moisture starch/sugar suspensions that will not ruboff on the heated toaster grating. Shelf stable toaster pastriesdefinitely fill a need in terms of convenience and provide excellentphysical integrity in the toasting process, but it is submitted thatthese products are not particularly appealing when compared with freshbaked goods.

[0005] Frozen toaster pastries, on the other hand, are excellentformulations of a toaster stable formula and include a more traditionalpastry shell with superior eating properties as compared with the shelfstable products. Unfortunately, however, fillings for frozen toasterpastries are limited in nature to what is appropriate within a pastryshell. Moreover, the process required to make frozen toaster pastries isquite specialized. Even with the availability of shelf stable and frozentoaster pastries, a very limited variety of toaster friendly productsare currently available in view of the popularity and demand for suchproducts in the consumer marketplace.

[0006] In general, it is submitted that current baking processes do notprovide for a broad line of products which may be safely andconveniently heated in an upright toaster. The present invention, incontrast, provides a highly advantageous method and associated apparatuswhich is capable of producing a wide array of products which areinherently suitable for re-heating in an upright toaster.

SUMMARY OF THE INVENTION

[0007] A method of producing a comestible and associated apparatus aredisclosed. In accordance with the present invention, a baking mixture isprepared having a moisture content. A mold arrangement is then providedhaving a mold cavity which is sealable from ambient pressure. The bakingmixture is placed in the mold cavity and the mold cavity is then sealed.Thereafter, the mold arrangement is heated with the baking mixturesealed therein such that pressure in the mold cavity rises above ambientpressure and a substantial portion of the moisture content in the bakingmixture remains in the mold cavity as the baking mixture heats to formthe comestible.

[0008] In one aspect of the invention, the baking mixture is formulatedto have a density which is approximately equal to the desired density ofthe comestible to be produced. Thereafter, the mold cavity of the moldarrangement is substantially filled with the density controlled bakingmixture. Baking is performed under pressure such that the densitycontrolled baking mixture is not permitted to expand significantly andthe moisture content of the density controlled baking mixture issubstantially retained thereby producing a comestible havingsubstantially the same density and moisture content as the densitycontrolled baking mixture.

[0009] In another aspect of the invention, a baked food productincluding a filling is surrounded by a baked layer. The improvementcomprises an edible encapsulant layer substantially surrounding thefilling and disposed between the filling and the baked layer. Theencapsulant layer is intended to which maintain separation between thefilling and the surrounding baked layer during initial baking and duringsubsequent storage and re-heating. In one feature, the encapsulant layeris formed of a protein encapsulated starch. In another feature, thefilling and surrounding encapsulant layer form a core pocket which isthen covered by an outer baking layer. The core pocket may be producedand stored under either refrigeration or frozen prior to incorporationin a pre-baked product for baking.

[0010] In still another aspect of the present invention, a bakingmixture is prepared including at least one leavening agent provided in apredetermined amount. The baking mixture is then baked in a way whichlimits expansion of the baking mixture to establish a baked density ofthe baked comestible and such that the predetermined amount of theleavening agent is sufficient to limit the time required for baking thebaked comestible. In one feature, the predetermined amount of leaveningagent is determined based on the leavening agent imparting anundesirable taste characteristic to the baked mixture. In anotherfeature, the predetermined amount of leavening agent is substantiallygreater than a minimum amount of the leavening agent capable ofproducing the baked density.

[0011] In still another aspect of the invention, a leavening agent ispresent in a predetermined amount sufficiently uniformly distributedthroughout a baking mixture at least forming a portion of the baked foodproduct such that the predetermined amount of said leavening agent inthe baking mixture is substantially greater than a minimum amount of theleavening agent capable of producing a baked density by causing thebaked product to fill the mold cavity. The portion of leavening agentabove the minimum amount contributes pressure which forces a portion ofthe baking mixture against the interior wall of the mold arrangement toform the portion of the baking mixture into a substantially de-aeratedcrust which surrounds a core portion of the baked food product wherebythe substantially de-aerated crust serves to substantially maintain thebaked outline of the baked food product when the product is re-heated,even if re-heated from an unfrozen state. In one feature, the corepocket of the present invention, including a filling surrounded by theforegoing encapsulant layer, may itself be surrounded by an outer bakedlayer including the enhanced substantially de-aerated crust of thepresent invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present invention may be understood by reference to thefollowing detailed description taken in conjunction with the drawingsbriefly described below.

[0013]FIG. 1 is a diagrammatic perspective representation, incross-section, showing a split mold arrangement which is manufactured inaccordance with the present invention showing an upper mold half in aposition that is separated from a lower mold half.

[0014]FIG. 2 is a diagrammatic perspective representation, incross-section, showing the split mold arrangement of FIG. 1 with theupper and lower mold halves in a contacting, closed position whichserves to define a mold cavity.

[0015]FIG. 3 is a diagrammatic perspective view, in cross-section,illustrating a baked article produced using the mold arrangement of FIG.1 shown here to illustrate the advantages of the present invention.

[0016]FIG. 4 is a diagrammatic view, in cross-section of a ring moldarrangement which is manufactured in accordance with the presentinvention.

[0017]FIG. 5 is a diagrammatic plan view of a lower heated platen andsteel ring mounted thereon which form part of the ring mold arrangementof FIG. 4.

[0018]FIG. 6 is a diagrammatic view, in elevation, of an automatedproduction system which incorporates a plurality of ring molds of thetype illustrated in FIGS. 4 and 5.

[0019]FIG. 7 is a diagrammatic plan view of a production moldarrangement manufactured in accordance with the present invention.

[0020]FIG. 8 is a diagrammatic perspective view, in cross-section,illustrating a filled baked article produced using the mold arrangementof FIG. 1 shown here to illustrate certain characteristics andadvantages of the filled baked article in accordance with the presentinvention.

[0021]FIG. 9 is a diagrammatic plan view illustrating an intermediatestep in producing a core pocket used in the filled article of FIG. 8showing a filling positioned on a sheet of encapsulant material.

[0022]FIG. 10 is a diagrammatic view plan view illustrating a furtherstep in producing the core pocket used in the filled article of FIG. 8showing the encapsulant material folded over the filling along with edgeportions of the encapsulant sheet sealed to one another partiallysurrounding the filling.

[0023]FIG. 11 is an elevational view, in cross-section, of the corepocket of FIG. 10 shown here to illustrate further details of itsstructure.

[0024]FIG. 12 is a diagrammatic perspective view illustrating the corepocket of FIGS. 10 and 11 positioned on a lower sheet of baking mixtureas an intermediate step in the formation of the baked article of FIG. 8.

[0025]FIG. 13 is a diagrammatic perspective view of a pre-baked articleproduced by covering the lower sheet and filling of FIG. 12 with anupper sheet layer of baking mixture and trimming the edges of thepre-baked article for subsequent baking to form the baked article ofFIG. 8.

DETAILED DESCRIPTION OF THE INVENTION

[0026] Attention is immediately directed to FIG. 1, whichdiagrammatically illustrates, in cross-section, one embodiment of asplit mold arrangement manufactured in accordance with the presentinvention and generally indicated by the reference numeral 10. Splitmold arrangement 10 includes an upper mold half 12 defining an uppermold recess 14 and a lower mold half 16 defining a lower mold recess 18.An electrical heating element 20 is positioned within each mold half.Electrical power is supplied to heating elements 20 by electrical cables22. The upper and lower mold halves may be formed from any suitablematerial such as, for example, stainless steel. Heating elements may beof any suitable configuration and arranged on or in the mold halves inany suitable manner provided only that the elements are in directcontact with the mold halves and the latter are heated in a sufficientlyuniform manner. The heating elements should be capable of maintainingtemperatures at the surfaces defining the mold recesses in the range ofapproximately 250° F. to 700° F. Moreover, any suitable heatingtechnique is contemplated such as, for example, gas heat appliedexternally to the mold.

[0027] Turning to FIG. 2 in conjunction with FIG. 1, the upper and lowermold halves include confronting surfaces 24 (not visible) and 26 (FIG.1). It should be noted that the cross-sectional view of FIG. 1 showsapproximately one half of the complete split mold arrangement 10 suchthat, when the mold halves are positioned as shown in FIG. 2 withsurfaces 24 and 26 in direct contact, a mold cavity 28 is defined byupper mold recess 14 and lower mold recess 18. Moreover, surfaces 24 and26 are machined to a predetermined degree of smoothness such that, whensufficient force is applied in the directions indicated by arrows 30 and32, a pressure seal is achieved which seals mold cavity 28 from ambientpressure, as will be described in further detail hereinafter.

[0028] With continuing reference to FIGS. 1 and 2, a description of theoperation of split mold arrangement 10 will now be provided. Initially,a pre-measured amount of a baking mixture 34 having a predeterminedmoisture content is placed into lower mold recess 18 with the upper andlower mold halves in the spaced apart position of FIG. 1. As will bedescribed in detail at an appropriate point below, baking mixture 34 maycomprise any form of dough, batter or preformed “dough ball” whichsurrounds a filling or any suitable food product. Generally, it isdesirable to preheat the mold halves before inserting the bakingmixture. The mold halves may, of course, be treated with a suitablerelease agent prior to placing the baking mixture into the lower moldrecess. Thereafter, the mold halves are brought into the closed positionof FIG. 2.

[0029] With the mold halves in their closed position and upon achievinga sufficient seal between the mold halves, the baking mixture is bakedin a highly advantageous way. Specifically, it should be appreciatedthat molding arrangement 10 provides for pressurized baking versusstandard oven baking. Since the moisture content of the baking mixtureis permitted to escape from the mold cavity only to a limited extent,evaporation of the moisture content of the baking mixture does not serveas a significant factor in cooling the baking mixture. Therefore, rapidbaking is achieved by holding the baking mixture at a higher temperature(compared with conventional baking) under vapor pressure, greater thanambient pressure, which results from the moisture content of the bakingmixture. Pressures of 0.5 psi to more than 20 psi above ambient pressureare readily achieved using mold arrangement 10. These pressures areaccompanied by increases in baking temperature of 5° F. to more than 80°F. above interior article temperatures as compared to a conventionalbaking environment. Moreover, the continuing presence of the moisturecontent of the baking mixture within the mold cavity advantageouslyprevents burning. It is to be understood that some small portion of themoisture content of the baking mixture may be permitted to escape frommold cavity 28 (i.e., the seal between the upper and lower mold halvesmay actually serve to regulate the desired baking pressure) whileachieving the advantages described above and still further advantages tobe described below.

[0030] Referring to FIGS. 1-3, once baking mixture 34 has been baked,the baked article 36 is removed from molding arrangement 10 by placingthe upper and lower mold halves in the open position shown in FIG. 1. Itshould be mentioned that one advantage of split molding arrangement 10resides in its ability to produce baked article 36 such that it includesappealing shaped edges 37. It should be appreciated that baked articlesmade using molding arrangement 10 generally share certain highlyadvantageous characteristics, irrespective of the specific formula ofthe baking mixture. In particular, the cross-sectional view of FIG. 3,illustrates that baked article 36 exhibits a continuous, compressed thinshell 38 having a thickness which may range from {fraction (1/64)} inchup to approximately ⅛ inch depending, for example, on the productformula, baking time and mold temperature. Thin shell 38 is produced asa result of the increased pressure within the mold cavity which forcesthe baking mixture against the heated mold surface such that the thinshell is dense and de-aerated relative to the interior 40 of bakedarticle 36. At the same time, interior 40 of the baked article remainsrelatively moist, depending, of course, on the moisture content of thebaking mixture used to form the baked article. Since thin shell 38 isrelatively strong as a result of its compressed, de-aerated nature, itserves to support the relatively moist interior of the article.

[0031] Still referring to FIGS. 1-3, further strength is imparted to thethin shell as a result of characteristics including caramelization andcrystallization as a result of contact between the baking mixture andthe heated mold surfaces. These characteristics are attributed to theknown interaction, under heat, of sugars and proteins within the bakingmixture. When the baked article of the present invention is placed intoa toasting environment, the de-aerated thin shell absorbs heat rapidly,eliminating moisture from the surface while simultaneously serving toencapsulate moisture in the interior of the baked article. Therefore,dry out of the article's interior is minimized during toasting. Stillfurther advantages of the present invention will be describedimmediately hereinafter.

[0032] Referring solely to FIG. 3, it has been discovered that thinshell 38 is particularly advantageous in the production of toasterfriendly frozen articles. In particular, the thin shell has been shownto re-conform to the original mold structure when re-heated in astandard toaster. In contrast, standard baking or broiling processes donot provide such an equivalently dense, de-aerated outer crust film.Products produced using standard baking processes and frozen in adeformed shape, therefore, tend to remain in such a deformed shapefollowing toasting. In addition, the crust on such products offerslittle in the way of a moisture retaining barrier such that the fillingsin these standardly produced products have a tendency to dry out. Itshould be mentioned that this problem is exacerbated with regard tofrozen products since they are typically placed in a toaster in a frozenstate. Toasting time is significantly increased for frozen productssince the filling must not only be heated, but thawed. In this regard,it is noted that primary size restrictions for baked articles intendedto be frozen and produced using the present invention are established inview of the time required for re-heating from the frozen state. Oneuseful set of dimensions for frozen baked articles has been found to bea thickness t of ⅜ inch to ⅝ inch and an overall rectangular shape ofapproximately 3 inches by 5 inches. Alternatively, the overall shape maybe circular, having a diameter of approximately 4 inches to 5 inches. Ofcourse, any desired shape may be produced with an appropriately shapedmold cavity.

[0033] In considering the wide array of products, including shelf stableproducts, which may be produced in accordance with the presentinvention, mold cavity volume may vary from less than 3 cubic inches to25 cubic inches or more in view of size limitations imposed by a typicalupright toaster. With regard to minimum volume, it should be rememberedthat the mold configuration should be established so as to provide abaked article which includes a moist center. If for example, the productis too thin, a primarily crust based item (i.e., mostly comprised of athin shell) will be produced. With regard to maximum volume, a thicknessof 1 inch with a height and width of 5 inches is considered as maximumsize for a standard upright toaster. However, larger sizes may beproduced for non-standard toasters.

[0034] Continuing with a description of the advantages derived in usingmold arrangement 10, it should be appreciated that baking times aresignificantly reduced. For example, items such as cookies and muffinscan be baked in approximately one-half the time required by conventionalprocesses. Moreover, baking time is consistent across a wide variety ofdifferent formulas. It is anticipated that most articles will bake inthe molding arrangement of the present invention within approximately4-6 minutes, as compared with times ranging from 8-30 minutes inconventional oven processing. In addition, the need for large continuousproduction ovens is eliminated. It is submitted that significantproduction savings will be realized for this reason alone.

[0035] As noted above, the present invention is highly advantageous inits ability to produce upright toaster compatible baked itemsessentially irrespective of the baking mixture which is used. It shouldbe appreciated that the present invention contemplates the production ofitems such as, for example, muffins, cookies, brownies, yeast pastry,biscuits and scones, cakes (ranging from pound cake to very light spongecake), soda breads, yeast breads (sweet and non-sweet) and filled doughproducts which may be filled with sweet or non-sweet fillings. Theseproducts, when produced in accordance with the teachings herein, willnot fall apart or break down while being toasted in a standard uprighttoaster and will maintain product integrity during removal from thetoaster. It should also be mentioned that even though the presentinvention is essentially universal in consistently producing baked itemsirrespective of the type of baking mixture used, it remarkably providesthat each of these items retains its expected taste, texture and eatingcharacteristics. In and by itself, this feature is highly advantageous.

[0036] Referring again to FIG. 1, molding arrangement 10 may include oneor more features which result in the formation of cavities ordepressions in the surface of the baked article to be produced. Forexample, projecting mold features 44 are shown as dashed lines in theupper mold recess such that a corresponding pattern of indentations isformed in the baked article produced thereby (not shown). It should alsobe appreciated that a variety of specialty products can be produced byfilling these cavities. For example, these products include pizza andfruit filled Danish suitable for vertical toasting. It should also beappreciated that the present invention provides the ability tomanufacture baked articles in a way which further enhances consumerappeal of known products. For example, mold arrangement 10 may beconfigured to form a “hybrid” muffin which has two tops, since it issubmitted that consumers prefer to eat the top portion of a conventionalmuffin. Still further advantages of the present invention will becomeapparent in the remaining discussion.

[0037] Turning now to FIGS. 4 and 5, one embodiment of a ring moldarrangement manufactured in accordance with the present invention isgenerally indicated by the reference numeral 60. Ring mold arrangement60 includes an upper platen 62 and a lower platen 64. The upper andlower platens include associated heating elements which are not shownfor purposes of simplicity and which are readily providable by one ofordinary skill in the art. Power cables 66 provide electrical power tothe platens. The platens are generally formed from materials such as,for example, stainless steel. A steel ring 68 is mounted on the uppersurface of lower platen 64, for example, by welding. It is to beunderstood that ring 68 need not be circular in form. In fact, anydesired shape may be used. Dimensions including the diameter of ring 68and its height may be established in view of the foregoing discussions.Steel ring 68 includes an upper edge 70 such that when the upper andlower platens are moved (not shown) in the directions indicated byarrows 30 and 32, respectively, a pressure seal is attained between theupper edge of the steel ring and the lower surface of the upper platen.In this way, a molding cavity 72 is defined which may receive bakingmixture 34 in the same manner as previously described split moldarrangement 10.

[0038] Still referring to FIGS. 4 and 5, in the sealed position, heat istransferred from the upper and lower platens into steel ring 68 suchthat consistent baking temperatures are produced. While other types ofmetal may be found to be useful in forming ring 68, it has been foundthat steel produces excellent results. The use of an aluminum ring wasfound to be unsatisfactory, resulting in inconsistent baking due toexcessive heat dissipation caused by the aluminum. One of skill in theart will appreciate that ring mold 60 operates in essentially the samemanner as previously described split mold arrangement 10. Moreover,baked articles produced by ring mold arrangement 60 share all of theadvantages of articles produced by mold arrangement 10. Therefore,descriptions of baking operations and the advantages of baked articlesproduced in accordance with the present invention will not be repeatedfor purposes of brevity and the reader is referred to previouslyappearing discussions. However, at the same time, one aspect of ringmold arrangement 60 has been found to be particularly advantageous, aswill be described immediately hereinafter.

[0039] In one technique for using ring mold arrangement 60, inaccordance with the present invention, a density controlled bakingmixture is formulated with a density which is equivalent to that of thefinished baked article to be produced using that baking mixture. Densityof the mixture can be controlled, at least in part, by pre-aerating orwhipping the baking mixture. In using the density controlled bakingmixture, ring 68 is entirely filled with the mixture as illustrated inFIG. 4. Thereafter, the upper platen is sealed against upper edge 70 ofring 68 and baking proceeds. The density and moisture content of theresulting baked article are, therefore, equivalent to that of the bakingmixture used to produce it. It is submitted that this technique ensuresconsistent results and provides significant advantages over prior artbaking methods.

[0040] Referring briefly again to FIG. 1, it should be appreciated thata single mold configuration filled entirely with the baking mixture mayreadily be provided by simply eliminating upper mold recess 14. In thisway, the technique described in the discussion immediately above may beemployed in which lower mold recess 18 can be completely filled with adensity controlled baking mixture.

[0041] Attention is now directed to FIG. 6 which illustrates anautomated system, generally indicated by the reference numeral 80, forproducing baked articles in accordance with the present invention.System 80 includes an upper platen conveyor 82 and a lower platenconveyor 84. For the reason that assembly 10 utilizes a number ofcomponents which are identical to those which make up previouslydescribed ring mold arrangement 60, like reference numbers are appliedto like components wherever possible and the reader is referred topreviously appearing descriptions of these components. Upper platenconveyor 82 carries a plurality of upper platens 62. Lower platenconveyor 84 carries a plurality of lower platens 64 each of whichincludes steel ring 68 installed thereon. During the operation of thesystem, the lower portion of the upper platen conveyor moves in unisonwith the upper portion of the lower platen conveyor in the directionindicated by an arrow 86.

[0042] Still referring to FIG. 6, the upper and lower platen conveyorsare arranged in proximity with one another such that a steel ring 68 aof a first ring mold arrangement 60 a is open to receive a suitablebaking mixture. In the present example, a predetermined amount of abatter 88 is dispensed into steel ring 68 a by a nozzle 90. Thereafter,as both of the conveyors move, the upper platen 62 a, which forms partof ring mold arrangement 60 a, comes around the end of the upper platenconveyor so as ultimately be brought into contact (not shown) with ring68 a once movement of the conveyors brings ring mold 60 a to theposition in which a ring mold 60 b is shown in the figure. At thisposition, each steel ring 68 is sealed by its respective upper platen 62as a result of the proximity of the upper and lower conveyors such thatbaking may then proceed under pressure in accordance with the teachingsof the present invention, as described above. Of course, electricalpower is provided as appropriate during the automated process beingdescribed. A series of ring mold arrangements 60 c through 60 h areshown ahead of the position of ring mold arrangement 60 b.

[0043] As each of these ring molds reaches the far end of the lowerplaten conveyor, baking is complete and the baked article within aparticular ring mold arrangement is ready to be removed. In the presentexample, ring mold arrangement 60 i is shown travelling around the endof the lower platen conveyor. As it does so, steel ring 68 i separatesfrom upper platen 62 i and, thereafter, a baked article 92 simply fallsout of ring mold 60 i and onto a product conveyor 94 which is moving inthe direction indicated by an arrow 96, for example, to transport thebaked article to a packaging operation. It should be appreciated that astep such as, for example, cooling the baked articles along a lattersection of the upper and lower platen conveyors is readily incorporatedin the manufacturing operation shown in the figure. Cooling may simplyinvolve turning off electrical heating power to the upper and lowerplatens of the ring mold arrangements at an appropriate point along theproduction line and/or routing the conveyors, for example, through acooling tunnel (not shown). In the instance where the baked articleincludes indentations/cavities produced, for example, by projecting moldfeatures 44 (FIG. 1) an additional step in the manufacturing process mayinclude filling the indentations with a preselected filling in a knownmanner.

[0044] It should be appreciated that automated system 80 represents ahigh throughput, energy efficient utilization of the teachings of thepresent invention. This system is intended as exemplifying only one formof an automated system which employs the teachings of the presentinvention. Therefore, any number of modifications (none of which areshown) may be performed on this system while remaining within the scopeof the present invention. For example, previously described split moldarrangement 10 or another such suitable mold arrangement may be used inplace of the plurality of ring mold arrangements used along the upperand lower platen conveyors. As another example, a dough ball or filleddough ball may be placed into the mold by known apparatus such asmechanical fingers. As still another example, the baked article may beremoved at the end of the production line by mechanical fingers in a waywhich avoids damaging the baked article as a result of falling. In yetanother example, the baked article might be removed from the ring moldsby creating a vacuum between the upper platen and the baked article. Thelatter may then be released by releasing the vacuum at an appropriatetime.

[0045] Turning to FIG. 7, a production mold arrangement 100 isillustrated. Mold arrangement 100 includes a large heated lower platenon which are positioned a plurality of steel rings 68. One of skill inthe art will recognize that mold arrangement 100 is used in the samemanner and shares the same advantages as one of previously describedsplit mold arrangements 10 or ring mold arrangements 60 except that aplurality of mold cavities 102 are provided for simultaneous use. Afterplacing a predetermined portion of baking mixture (not shown) intocavities 102, the latter are covered by a large heated upper platenwhich is not shown for purposes of clarity. It is noted that a pluralityof individual heated upper platens may be used as wherein each cavity102 is sealed by an individual upper platen. While arrangement 100 hasbeen described using the ring mold configuration of FIGS. 4 and 5 (i.e.,each mold cavity is essentially defined by one of the mold halves), itshould be appreciated that the use of a split mold configuration or anyother suitable, pressure retaining configuration is contemplated.

[0046] From the foregoing discussions, it is evident that the presentinvention provides a universal process for the production of toastercompatible baked articles which exhibits consistent results across awide range of baking mixture formulations. Therefore, a great variety ofdifferent products may advantageously be produced using one relativelysimple apparatus. Moreover, the present invention contemplatesefficiency and high throughput by dramatically reducing baking times ascompared with conventional oven baking. It should be mentioned thatwhile the present invention directly addresses the production of toastercompatible products, these products are suitable for re-heating in otherways such as, for example, by using a toaster oven.

[0047] As described above, fillings have been particularly problematicwith regard to reheating in a toaster environment. Many prior artproducts have been provided in frozen form for reasons to be describedbelow. In this regard, it has been discovered that the de-aerated crustof the present invention serves in a highly advantageous way duringre-heating. That is, the de-aerated crust serves not only to re-conformto its original mold outline and to prevent moisture from escaping fromthe product interior, but also conducts heat to the interior of theproduct. The product can therefore be warmed up in a standard toastingenvironment in a way which thaws the frozen interior, including a frozenfilling, usually in a single cycle without over browning or excessivetoasting of the outer surface of the de-aerated crust. As a result ofthe ability of the product to absorb heat, change in the appearance ofthe product is limited within normal reheating limits.

[0048] Turning now to FIG. 8, a filled baked article produced inaccordance with the present invention is generally illustrated by thereference number 150. Because filled baked article 150 is produced usingsplit mold arrangement 10 of FIGS. 1 and 2, it is similar in a number ofrespects to previously described baked article 36 of FIG. 3. Inparticular, filled baked article 150 includes appealing shaped edges 37.More importantly, an enhanced thin de-aerated crust or shell 151 is alsopresent. Enhanced thin crust 151 is similar to previously described thincrust 38 with the exception of certain differences which will bedescribed at an appropriate point below.

[0049] In accordance with the present invention, filled baked article150 includes a filling 152, which is surrounded by a thin, edibleencapsulant layer 154 having characteristics to be described in detail.The combination of encapsulant layer 154 and filling 152 may be referredto as a core pocket 155. The latter is, in turn, surrounded by an outerlayer 156 which is formed from previously described baking mixture 34. Aportion of baking mixture 34 forms enhanced de-aerated crust 151.

[0050] Still referring to FIG. 8, in accordance with the presentinvention, encapsulant layer 154 is formed using a protein encapsulatedstarch, which may alternatively be referred to as a pasta. As described,for example, in Dough Rheology and Baked Product Texture, edited byHamed Faridi and John M. Faubion, published by Van Nostrand Reinhold,1990, the microstructure of pasta is such that the surface of freshlyextruded or rolled pasta is a continuous protein film. The inner portionof pasta is a compact structure of starch granules embedded in anamorphous protein matrix. Starch granules and protein are aligned inlayers parallel to the protein film on the surface of the pasta. Afterproper drying, there is essentially no change in this structure.Improper drying or elevated dough temperatures disrupt the continuity ofthe protein film and the underlying matrix. While pasta is being cooked,protein hydration and starch gelatinization move from the surface of thepasta inward toward its center (Grzybowski and Donnelly, 1977). In theinstance of good quality pasta, the protein absorbs water causing theprotein to swell more rapidly than the starch. The result is acontinuous fibrillar network of denatured protein which surrounds thegelatinized starch granules (Resmini and Pagoni, 1983).

[0051] In comparison, most dough-based products use combinations ofstarch, protein and water to obtain appropriate structure which isgenerally a complex of starch, water and protein, with the protein beingin a matrix structure rather than forming a continuous fibrillar networkas in a pasta system. Thus, what differentiates products defined aspasta from normal bread, pastry and other dough-like products relates toutilization of protein in the structure relative to partially or fullygelatinized starch (gelatinized starch being starch swollen with wateras opposed to a starch granule or crystal). As another difference,protein derived from the flour base in pasta (wheat, rice or othergrains) forms the exterior protein film structure on the outsidematerial, described above, to encapsulate the starch.

[0052] When cooked, for example by par boiling, the cookedcharacteristics of pasta are defined by the described microstructure,assuming overcooking is avoided. The starch imbibes water and expands,while simultaneously being trapped in the protein film. The term “aldente” is used to describe optimum eating characteristics of cookedpasta relating to the starch being very turgid or swollen withoutbreaking through the protein film. This is similar to a balloon beingover-filled with water prior to breaking. The exterior protein filmcoupled with that turgidity also provides a slippery characteristicwhich allows pasta to be a base for sauce without absorbing the sauce.The present invention relies on the impervious nature of the outerprotein film layer to maintain filling integrity in a baked filledproduct so as to “entrap” the filling during baking and subsequentreheating. In and by itself, the ability to sufficiently maintain theintegrity of a filling pocket is a significant accomplishment in bakedgoods suitable for reheating in a toaster. The overall characteristicsof encapsulant layer 154 have been found to be highly advantageous inthe present application. In this regard, the encapsulant layer has beenfound to serve as an effective barrier to both oil and water basedfilling materials. That is, the filling may be comprised of oil and/orwater containing materials such as, for example, cheddar cheese, tomatosauce, chocolate, custard, cream cheese, sour cream, straight puremargarine or butter, flavored olive oil among many others. This resultis attributable to the impervious nature of the protein film as againstboth oil and water. Other characteristics of encapsulant layer 154 as abarrier layer for use in a food product will be discussed belowfollowing a brief discussion of related aspects of the prior art.

[0053] In the prior art, the problem of encrusting of fillings intoaster reheatable products has typically been addressed using a highfat pastry-like crust. In fact, the fat content may exceed the flourcontent. This approach is somewhat effective in the instance of waterand fat based fillings. Unfortunately, however, this solution may besignificantly limited in effectiveness if a filling such as cheese isutilized which is likely to undergo rapid expansion during baking. Ahigh fat pastry shell has been observed to often break or allow thecheese to leak out during either the baking or toasting processes. It issubmitted that a fat barrier layer serves poorly in resisting expansionby a filling having a tendency to expand more rapidly that the pastryshell during a baking or reheating process. A very high fat pastryshell, such as found in a fried pie, tends to hold high levels offilling and is generally suited to a toaster environment. That is, thehigh fat content rapidly absorbs heat and serves to minimize bum-up ofthe shell, although containment of high fat fillings remains a concern.For example, high levels of a cheese material may break through, due torapid expansion of the cheese against a rigid high fat shell. For thesereasons and more reasons yet to be described, the present inventionconsiders a high fat approach to encapsulant layer 154 as being anunacceptable solution for stabilization of fillings in a baked productduring a baking process or during subsequent toaster reheating.

[0054] In an attempt to cope with the problems presented by filledtoaster products, modifications have been made to assist theeffectiveness of a high fat pastry type shell. For example, relativelylow ratios of filling to shell have been used or very thin fillinglayers have been employed. While these approaches are effective,consumer appeal may be reduced considerably since the amount of fillingis quite limited. Unfortunately, even under low filling ratio or thinfilling layer conditions, filling materials such as Swiss cheese orcheddar cheese may continue to be problematic by leaking out of the highfat shell. Moreover, Applicants are unaware of the use of an encapsulantlayer in the in the interior of a food product serving to entrap afilling.

[0055] Still referring to FIG. 8, it should be appreciated thatencapsulant layer 154 of the present invention is advantageouslycomprised of a material having rubber or elastic-like characteristicsand is, at the same time, solid and non-aerated in nature while beingdough based. Unlike state of the art pastry systems which use a crustdefined by a high fat content characteristic, the encapsulant layer ofthe present invention is readily formulated with little or no fatpresent. In this regard, the encapsulant layer of the present inventionfunctions in a dual capacity as a fat and/or water barrier, wherein thefat barrier characteristic is critical to the encapsulation of materialssuch as cheeses and sauces having an oil/fat content. One advantageousaspect of the rubber-like characteristic of encapsulant layer 154resides in its ability to expand. Specifically, fillings of either wateror oil-based materials may be permitted to expand significantly withinencapsulant layer 154 without rupturing the membrane of the encapsulantlayer. Actual testing using filling materials such as, for example,cheese sauce, chocolate sauce, salsa and others have exhibited aremarkable ability of encapsulant layer 154 to maintain the integrity ofa pool of liquid or semi-liquid filling material in the core of aproduct as compared with prior art approaches. In this regard, thepresent invention contemplates a wide range of possible fillings, aswill be described at an appropriate point below.

[0056] With continuing reference to FIG. 8, another advantage ofencapsulant layer 154 is found in its eating characteristics uponwarming in a toasting environment. Remarkably, one attribute ofencapsulant layer 154 which makes this encapsulant so appropriate forits intended application is the imperceptible nature of the encapsulantlayer upon consumption. That is, the encapsulant layer melds in with thebaking mixture of which outer layer 156 is composed and essentially doesnot impart any of its own characteristics to outer layer 156. It isnoted that this characteristic is present immediately after baking andremains even if the product is reheated. At the same time, encapsulantlayer 154 serves to maintain the separation between filling 152 andouter layer 156. The importance of maintaining this integrity issignificant since penetration of filling 152 into outer layer 156 willmost generally produce a soggy or doughy texture in outer layer 156which is unpleasant to the palate. Moreover, the isolation between thefilling and outer layer is maintained irrespective of the formulation ofthe filling, be it either oil and/or water based. Encapsulant layer 154further serves during reheating by expanding in response to expansion offilling 152 during the reheating process in a toasting environment,generally conforming to the outline of the filling.

[0057] It should be mentioned that, prior to the development ofencapsulant layer 154 using a pasta-like formulation, a number of otherapproaches have been formulated and tested by Applicants. One of thesealternative approaches is based on the use of a cellulose based ediblefilm as encapsulant layer 154. Tested films include hydroxy propalcellulose and methyl cellulose. Unfortunately, it has been discoveredthat these films under heat and in the presence of moisture simplydissolve into water present in the adjacent dough and/or fillingmixture. Therefore, the cellulose film approach is considered as beinginferior. As another approach, a thin film denatured protein structurewas formed using cheese. Such a structure can be formed, for example,using cheese layers in the presence of microwave energy. While adenatured protein filling “bag” or barrier has been successfully createdin this way, the eating characteristics of the bag are orally detectableand difficulty is encountered in sealing the bag with the fillingtherein. Nonetheless, fillings have been successfully retained by thedenatured protein bag even using the pressure baking technique of thepresent invention. Depending upon the combination of filling andsurrounding layers, the denatured protein bag may prove to be use inapplications such as, for example, cheese fillings.

[0058] As described above, filled baked food product 150 has beenproduced in accordance with the pressure baking method of the presentinvention to form enhanced thin crust 151. In this regard, it should beappreciated that pressure baking serves to emphasis certain advantagesof encapsulant layer 154 when the use of a filling is desired. Forexample, problems encountered in producing a filled product aregenerally exacerbated by pressure baking. Fillings may readily expandduring the pressure-baking process, causing the filling to explode outof the product in the absence of encapsulant layer 154 once the productis released from the molds. Alternatively, during product cooling afterbaking, the filling may shrink, tending to leave air space when cooled.Encapsulant layer 154 of the present invention has been found to respondremarkably well in either of this situations. Due to its elastic nature,the encapsulant layer tends to maintain conformity with the filling inresponse to both expansion and shrinking of the filling.

[0059] Another problem, which is generally increased in magnitude bypressure baking, resides in fillings intermixing with surrounding bakedouter layers, losing the filling identity and possibly causing the outerlayer to become soggy, as described above. Again, encapsulant layer 154of the present invention has proven to be remarkably effective ineliminating this problem. The integrity of core pocket 155 has beenfound to be highly resistant to breach of any kind by a wide range offillings under normal pressure and non-pressurized baking conditions andin a typical toaster warming environment. It should be mentioned thatthe use of encapsulant layer 154 is contemplated in the production ofbaked goods without the use of pressure baking techniques. For example,products not intended for re-heating such as, for instance, a fruit piefilling within a cake type structure may be produced using theencapsulant layer and core pocket of the present invention. At the sametime, it should be appreciated that the use of the pressure bakingtechnique of the present invention is considered to be highlyadvantageous when used in combination with the filling core pocket ofthe present invention, as will be described immediately hereinafter.

[0060] With continuing reference to FIG. 8, it should be appreciatedthat filled baked food product 150 represents a highly advantageoussystem, particularly with regard to toaster reheatable products. Thissystem includes two components. The first component of the system isencapsulant layer 154 which serves as a pliable membrane to containfilling 152. While the encapsulant layer is highly advantageous in andby itself, it is intended to define the overall outline of a product toa limited extent in a filled toaster reheatable product. The secondcomponent of the system is enhanced thin crust 151. The latter providesmore than an adequate degree of support for the encapsulant layer andintervening baked outer layer 156 in defining an outline suitable fortoaster reheating, particularly in consideration of filled frozenproducts suitable for toaster reheating. In this regard, it should beappreciated that enhanced thin crust 151 is not only dense andde-aerated upon initial removal from its mold, but is also quite devoidof moisture. However, any product, during frozen storage, will tend toequalize in moisture content. That is, thin crust 151 will tend toabsorb moisture. As described above, when placed into a toasterreheating environment directly from a frozen state, the thin crust/shellalmost immediately dries out. Upon this drying, the initial strength ofthe thin shell in its dry state is substantially restored. In fact, thisdrying has been found to be complete substantially prior to thawing ofthe frozen filling of the product. At the same time, the thin crusttends to “remember” its initial molded outline and returns to that shapeas it dries. Therefore, enhanced thin shell 151 serves to compliment thefunction of encapsulant layer 152 in an ideal manner. That is, by thetime, filling 152 and encapsulant layer 154 have thawed to the point ofrequiring physical support, thin crust 151 has dried and is more thancapable of providing the required support. In this regard, previouslydescribed thin crust 38 of FIG. 3 is also well suited in the applicationof frozen filled products. It is submitted that this system, with thecombination of these two components, is highly advantageous and has notbeen seen heretofore in a pre-frozen filled product suitable for warmingin a toaster environment. Further advantages specifically associatedwith enhanced thin crust 151, as well as its method of manufacture, willbe described below.

[0061] In accordance with the present invention, it has been discoveredthat the advantages of the pressure baking method described above areenhanced in significant ways by formulating baking mixtures in aspecific manner. In particular, high levels of leavening agents areused. Leavening agents typically emit a gas such as carbon dioxide whencombined with water and then heated above a minimum temperature which isreadily exceeded in a baking process. These leavening agents include,but are not limited to baking powder and baking soda.

[0062] In standard baking practice, normal levels of leavening agentscontribute a lightness to baked goods by entraining the emitted gas inthe baked goods to form small voids during baking. If an excessiveamount of leavening agent is added to a baking mixture, the normalresult is an overflow wherein the volume of the baking mixture increaseswell beyond the size of the vessel in which it is being baked. In theprior art, adding excess leavening agent is therefore viewed as being adetriment and, in fact, as being wasteful.

[0063] Excess leavening agent can readily be defined as any amount ofleavening agent beyond a minimum amount which would increase the volumeof a baked good beyond a desired size or volume when expansion isunconstrained. In this regard, it should be appreciated that thepressure baking method of the present invention also serves to controlthe density of the baked product to be produced. Even in the presence ofexcess leavening agents, the baked product can only expand to the extentpermitted by the mold cavity. Remarkably, when excess leavening agent isadded to baking mixtures such as the baking mixture used to produceouter layer 156 in FIG. 8, two unanticipated benefits are produced.First, baking time is shortened significantly. It is now appreciatedthat the addition of the excess leavening agent causes pressure in themold cavity to rise significantly due to gases released by the excessleavening agents. In a repeatable test, a product previously requiring 7minutes baking time at a mold surface temperature of 350° was baked inapproximately 4.5 minutes using the same 350° mold surface temperaturesimply by adding excess leavening agent. Thus, baking time was reducedby more than 35%. In and by itself, this is a sweeping advantage incontemplation of high production commercial bakeries. Furthermore, theresult was a more uniform product as well as improved eating and flavorcharacteristics. Baking time may be reduced still further by increasingthe mold surface temperature, as will be described.

[0064] A second, highly advantageous benefit of the use of excessleavening agent in the pressure baking method of the present inventionis related to the characteristics of enhanced thin crust 151.Specifically, enhanced de-aerated crust 151 gains a significant degreeof strength due to the increase in baking pressure caused by the excessleavening agent. Generally, the properties of the thin de-aerated crustare thought to remain essentially unchanged, however, its density issubmitted to be increased and its uniformity is submitted to be improvedby the excess leavening agent. Filled baked product 150 was describedabove as being pre-frozen and placed directly into a re-heatingenvironment in this frozen state. In this regard, it should beappreciated that thawed fillings have been quite problematic in theprior art. Fillings that are quite liquid when thawed, and possibly evenmore liquid upon heating, are of particular concern due to an increasedtendency to penetrate and leak out of surrounding layers. With liquid orliquid-like fillings in a fluid state prior to reheating, more time isavailable during which penetration of surrounding layers can occur.Applicants believe that the non-availability of baked products (1)having liquid or near liquid fillings and (2) designed to be storedwithout freezing is attributable to the foregoing problems.

[0065] Aside from the prior art inability to sufficiently encapsulate aliquid filling, it is submitted that a third important reason for thelack of refrigerable liquid filled baked goods resides in the selfsupport required in a liquid filled product. It should be appreciatedthat a frozen filling is essentially self supporting by virtue of thefact that the product remains frozen until warmed. In a non-frozen orrefrigerable product, the shell or crust of such a product does notenjoy the benefits of a rigid, frozen filling which are limited tostorage and handling purposes. For this reason, the pastry shells ofprior art frozen products are generally incapable of adequatelysupporting a non-frozen filling prior to reheating. If such a product isallowed to thaw prior to being reheated in a toasting environment, theproduct will most likely break apart or leak filling upon being handled.The present invention substantially resolves these problems in theinstance of refrigerable liquid or semi-liquid filled baked productssuitable for reheating in a toaster environment, as will be described.

[0066] Referring again to FIG. 8, baked filled product 150 has proven tobe effective with regard to refrigerated storage. This advantage isattributed to the system combination of enhanced thin shell 151 andencapsulant layer 154. The latter serves, as described above, to retainfilling 152, even in a generally liquid state, within core pocket 155.At the same time, enhanced thin crust 151 provides a degree of supportin forming the overall outline of the product which has not been seenheretofore. The excess leavening agent technique of the presentinvention is thought to improve the characteristics of enhanced thincrust 151 to a degree which causes the enhanced crust to be relativelyresistant to moisture penetration even in a refrigerated environmentover a relatively long period of time. Therefore, enhanced thin crust151, in cooperation with encapsulant layer 154, results in practical,refrigerator stable, toaster reheatable products which may containfillings with liquid-like characteristics. Of course, semi-liquid,semi-solid or solid fillings are extremely well suited for use in theencapsulant system with either of enhanced thin crust 151 or thin crust38 produced in accordance with the pressure baking method of the presentinvention. Non-filled baked comestibles may advantageously be producedhaving enhanced thin crust 151. For example, muffins, cookies andvirtually any dough or batter based product that is produced with theenhanced thin crust of the present invention will not crumble or fallapart in a toaster while the inner core of the product remains moist andexhibits the same eating characteristics of that particular product aswhen produced in normal baking.

[0067] It should be appreciated that a particular limitation exists withregard to the use of excess leavening agents in accordance with themethod of the present invention. This limitation is not related topressure produced during baking, but rather to the taste characteristicsof the leavening agent employed. Most leavening agents have acharacteristically unpleasant taste. For example, baking soda containssodium bicarbonate which is characterized by a salty taste. At somepoint, when excess leavening agents are added to a baking mixture, thischaracteristic, undesired taste or flavor will become apparent in theoverall taste of the product. Therefore, the point at which theundesired taste is noticeable is considered as an upper limit for excessleavening agent content. During testing, excess leavening agents havebeen added in the range of approximately 50% to 200% above levelsspecified in standard baking formulations. Using this range of excessleavening agents, enhanced thin crust 151 was produced, accompanied by areduction in baking time in the range of approximately from 25 to 50%.

[0068] At some point above doubling the normal amount of leaveningagents, the upper taste limit will be encountered at which the undesiredtaste characteristic of the leavening agents will become problematic. Itshould also be appreciated that some recipes may encounter the leaveningagent taste limit at relatively lower levels dependant upon the specifictaste attributes of the recipe. Until the point at which the taste limitis reached, the characteristics of the enhanced thin crust of thepresent invention continue to improve as the amount of leavening agentis increased. Therefore, in most products, it is anticipated thatleavening agents should be added to just below the taste limitation soas to maximize the characteristics of enhanced thin crust 151.

[0069] Another, less important limitation exists with regard to the useof excess leavening agents. In some instances, for example, a productmay become overly brown with the use of excess leavening agents.Therefore, in some recipes, this browning factor may define the upperlimit of the content of excess leavening agents.

[0070] Still considering the method of the present invention with regardto producing enhanced thin crust 151 as accompanied by a reduction inbaking time and with reference to FIG. 2, surface temperatures of moldarrangement 10 should be adjusted upward in the range of approximately 5to 50 degrees F. in order to most fully realize the advantages of theexcess leavening agent technique of the method of the present invention.This temperature increase serves to further expedite pressure build upwithin the mold cavity which may even further improve the desiredcharacteristics of enhanced thin film crust 151.

[0071] Applicants submit that the highly advantageous use of excessleavening agents, as described herein, has not been seen heretofore.That is, it is neither normal nor known to add additional levels ofleavening agent beyond what is required in standard recipes. In fact,the use of excess leavening agents is impractical in the absence of theteachings herein with regard to density controlled baking.

[0072] Still referring to FIG. 2, with regard to mold arrangement 10,the machined characteristics of surfaces 24 and 26 may be used tocontrol the degree of pressure seal between the confronting mold halves,as described above. In addition, it has been discovered that enhancedthin crust 151 can be formed effectively with sufficient bias of themold halves against one another. Moreover, this bias is readily achievedwithout the need for a locking mechanism which locks the mold halvestogether. In accordance with the present invention, the mold halves maybe resiliently biased using springs (not shown) or upper mold half 12may be simply be weighted to provide a sufficient pressure seal. In thisregard, it has been found that a weight in the range of 10 to 20 poundsof pressure per square inch on sealing surfaces 24 and 26 produces thecontemplated results when the sealing surfaces include a width ofapproximately {fraction (1/16)} to ⅛ inches. It should be appreciatedthat, in the prior art, production line baking equipment typicallyemploys somewhat complicated locking mechanisms which serve to lock moldhalves against one another. Due to considerations such as mechanicalwear of the mold halves, such locking mechanisms can be problematic andunreliable. The elimination of the need for mold locking mechanisms inaccordance with the present invention is considered to be highlyadvantageous. It is noted that excellent results have been achieved bythe present invention even when the mold halves separate slightly nearthe end of the baking time. This result suggests that the thin crusts orenhanced thin crusts of the present invention are formed during thatinitial portion of baking time when the baking mixture is quite fluidand under significant pressure.

[0073] Filled baked product 150 may be produced with a wide range offillings, as mentioned. Products include simulated bread formulas filledwith cheese. In this regard, low fat cheeses have been found to produceexcellent results. In the prior art, low fat cheese has been problematicprimarily due to its poor melting characteristics. In the method of thepresent invention, pressure baking at substantially high temperatureuniformly melts low fat cheese causing it to be quite liquid. At thesame time, encapsulant layer 154 prevents leakage of the cheese duringboth pressure baking and product reconstitution in a toastingenvironment. In actual testing, an excellent cheese effect with regardto eating characteristics has been achieved using low fat cheese withvirtually no leakage of the cheese outside of its core pocket. Low-fatcheese in conjunction with meat and other materials also has been foundto produce filled sandwiches with excellent eating characteristics. Itshould be appreciated that without the core pocket of the presentinvention, virtually any type of cheese placed in bread will result in awide dispersion of cheese throughout the bread and no heavy pocket ofcheese. However, cheese placed in the core pocket of the presentinvention will result in a highly defined center pocket of cheese withinthe bread rather than dispersed cheese particles. The present inventionis highly advantageous in any filled good where a dense or heavy pocketof filling is desired. For this reason, the present invention is alsoapplicable in the production of baked goods in which filling is normallyinjected after baking specifically to achieve a dense, heavy fillingpocket. For example, custard filled doughnuts are normally producedusing injected filling.

[0074] Turning to FIGS. 8 and 9, the method of the present inventionwill now be described in further detail. FIG. 9 illustrates a sheetportion 160 of encapsulant layer material, in a pre-cooked state, havinga portion 162 of filling 152 positioned thereon for encapsulation. Sheetportion 160 may be formed, for example, using a mixture of wheat gluten(wheat protein), durum flour (from durum wheat), eggs and water. It isnoted that eggs are not required. Other ingredients may be substitutedfor or added for purposes of further enhancing the barrier capabilitiesof encapsulant layer 154 (FIG. 8) to ultimately be formed or for otherreasons, including, but not limited to wheat gluten, dried egg albumen,vegetable based albumen and various surfactants. Dry ingredients aremixed in a suitable manner while liquid (water and eggs, if used) areslowly added. Initially, the mixture will develop a wet, granularconsistency during mixing. Further mixing then releases sufficientprotein from the wheat or gluten containing ingredients, resulting inbinding the mixture into a continuous pasta dough. That is, a proteinencapsulated starch dough. Thereafter, the pasta dough mixture isallowed to cool and rest briefly. It is noted that bread dough, havinghigher levels of water would begin to rise at this stage because of theactivity of yeast present in the dough or other organisms, since thesmall amount of water present in the pasta dough mixture does not allowgas-forming organisms to function. If, however, the pasta dough mixtureis left long enough at room temperature, moisture on the surface willresult in mold growth and so should be avoided. The pasta dough mixtureproduct can be used once cooled or refrigerated or even frozen, thawedand used at a later time. A portion of the pasta dough mixture can thenbe rolled out to form sheet portion 160 including a thickness in therange of approximately 0.005 inches to 0.010 inches. It should beappreciated that the sheeting process or rolling out process helpsfurther distribute and form the protein film, contributing further tothe unique characteristics of encapsulant layer 154 within a final bakedproduct.

[0075] Alternatively, sheet portions of the pasta dough mixture can beformed rapidly from the original bulk mixture using extrusion. However,extrusion generally will not give the most optimum protein filmstructure in encapsulant layer 154. In fact, this difference should beconsidered when fillings such as cheese, which are traditionallydifficult to encapsulate are to be used in a toaster stable product.Therefore, the more the pasta dough mixture is subjected to sheetingaction (i.e., repeated steps which result in a progressively thinnersheet), for example, between pressure rollers, the better developed arethe protein film characteristics of sheet portion 160. Sheeting affectsthe strength of the pasta dough mixture in a positive way. A strongermixture is more resilient and, therefore, is appropriate for use whenrolled thinner than a corresponding “weak” dough. Nonetheless, evencrude extrusion production is likely to produce an effectiveencapsulation barrier so long as sufficient protein structure isgenerated.

[0076] Referring to FIGS. 10 and 11, sheet portion 160 is folded overfilling portion 162 and edges 164 surrounding the filling portion aresealed against one another. Sealing can be accomplished, for example, bypressing. During this step, efforts should be made to remove excess airfrom an encapsulation pocket 166 containing filling portion 162. Edges164 may be trimmed to eliminate excess dough at these edges.

[0077]FIG. 12 illustrates core pocket 155 following the additional stepof cooking (not shown) the raw core pocket for a short period of time,for example, in boiling water. The cooking step realizes the desiredprotein film structure characterizing encapsulant layer 154. It is to beunderstood that this cooking process can be done in many ways including,but not limited to steaming, hot water spray on a production line, acontinuous bath or any combination thereof. As described above, sheetportion 160 will swell and become turgid in the cooking process informing encapsulant layer 154. The cooked sheet portion is moretranslucent than its uncooked counterpart and, depending upon thethickness of the encapsulant layer, may approach transparence. The waterimbibed in cooking the encapsulant layer results in the gel-likecharacteristics useful in the barrier function of the encapsulant layer.It is noted that pasta dough sheet portion 160 should not be pre-cookedprior to sealing filling therein to form a core pocket since the desiredfilm characteristics post-cooked sheet portion are likely to result ingreat difficulty in sealing the core pocket.

[0078] Core pockets may be frozen after being sealed or par cooked andthen frozen as alternatives to immediate use. Frozen core pockets,pre-cooked or otherwise, may be stored for an long periods of time andused when appropriate.

[0079] Having described one manner of forming core pocket 155, it shouldbe appreciated that the core pocket may be formed in a great number ofalternative manners (not shown) even in a commercial production linesetting. For example, mold arrangements may be used in which sheetportions of the pasta dough mixture are laid across a plurality of moldcavities defined in a lower mold half. Filling portions may then beplaced in the cavities onto the lowermost layer of pasta dough. It isnoted that this technique may utilize a liquid filling. Thereafter, asecond sheet of pasta dough is laid across the mold arrangement coveringthe filling portions and contacting the lowermost layer therebetween. Anupper mold half is then aligned and pressed against the lower mold halfto force excess air out of the mold cavities while sealing the fillingportions in the mold cavities and separating the sealed core pocketsfrom one another. With an appropriate lower mold half configuration (notshown), the need for an upper mold half may be eliminated. That is, forexample, a roller may be rolled across an appropriately configured lowermold half to accomplish sealing and separation of the core pockets.

[0080] It is contemplated that a conventional ravioli production line isadvantageously adaptable to the present invention to the extent offorming core pockets. In this connection, continuous upper and lowersheets of pasta dough mixture can be brought together with placement offilling portions therebetween in an automated production line. Ofcourse, the core pockets are not intended for consumption at this stagein production and subsequent use of the core pockets in the baked foodproducts of the present invention requires additional steps, as will bedescribed.

[0081] Referring to FIG. 12, cooked core pocket 155 is placed on a sheet170 of baking mixture 34. The latter may be bread dough including yeastand chemical leavening agents. In order to develop bread-likecharacteristics and depending upon the baking technique to be used, acertain amount of development time for dough containing yeast may bepermitted. If the pressure baking technique of the present invention isto be used, the baking mixture may be allowed to rise once to contributeto its bread-like characteristics such as, for example, dough may doublein volume and then is kneaded or sheeted to its pre-rise density.However, a second rise immediately prior to baking is not considered asbeing necessary. Layer 170 is then coated (not shown) with a starch andwater paste to insure that the core pocket adheres to the properlocation and that this layer adheres to a subsequent layer to bedescribed. The starch and water base may be applied, for example, byspraying or light brushing. Its application over the core pocket has nodetrimental effect on the characteristics of encapsulant layer 154 anserves to fix subsequent layers to be described below. Depending uponthe characteristics of the baking material including its moisturecontent, the application of an adhesive starch/water or similar suchmixture may not be needed. It should be appreciated that more than onelayer of baking material may be applied. In fact, alternating layers ofvarying or like thickness may be used having differing flavor and/orcolor characteristics.

[0082] Referring to FIGS. 12 and 13, following application of thestarch/water mixture, a second baking mixture sheet 172 is placed oversheet 17 and sealed thereto, for example, by light pressure. Excessbaking mixture may be trimmed away to form a pre-baked article 174. Thelatter may then be baked in any suitable manner including the pressurebaking technique of the present invention, for instance, using moldarrangement 10 producing baked product 150 of FIG. 8 with all of itsattendant advantages, as described above. Of course, application ofbaking layers 170 and 172 along with placing of core pockets 155 mayreadily be accomplished in a high speed production line environment.Subsequent baking using the pressure baking technique of the presentinvention will further enhance such a production line environment sincebaking times are significantly reduced as compared with conventionalbaking.

[0083] Still considering pre-baked product 174 as used to produce bakedproduct 150 with the pressure baking technique of the present invention,the baked end product is a baked dough or batter product havingcharacteristics controlled by the baking mixture itself. For example,bread dough, muffin batter and biscuits dough, among others, but with acore pocket in the center containing the appropriate filling. The corepocket serves to prevent leaking of the filling into a more aeratedsurrounding dough, in the absence of which the dough or batter willabsorb the fluids in an undesirable way. Moreover, the finished productincludes toaster stable crust shell 151, allowing for rapid reheating ofthe filling without burning the crust due to its multiple abilities torapidly transfer heat into the filling while lending sufficient support,even in the instance of liquid fillings, and to prevent undesired escapeof moisture from the filling. At the same time, the crust dries rapidlyupon reheating to enhance its strength and then resists burning byefficiently conducting heat into the filling. These advantages of theenhanced thin crust are attributed to its increased densitycharacteristics. Accordingly, filled baked product 150 can be frozen andreconstituted in a toaster by reheating in a single cycle. The fillingreheats, but leaking is avoided due to its encapsulation within theencapsulation layer of the present invention.

[0084] One skilled in the art may devise many alternative configurationsfor the arrangements and methods disclosed herein. Therefore, it shouldbe understood that the present invention may be embodied in many otherspecific forms without departing from the spirit or scope of theinvention and that the present examples and methods are to be consideredas illustrative and not restrictive, and the invention is not to belimited to the details given herein, but may be modified within thescope of the appended claims.

What is claimed is:
 1. In a baked food product including a fillingsurrounded by a baked layer, the improvement comprising: an edibleencapsulant layer substantially surrounding said filling and disposedbetween the filling and the baked layer, said encapsulant layer servingin a way which maintains separation between the filling and thesurrounding baked layer, at least to a limited extent, during initialbaking and during subsequent storage and re-heating.
 2. The improvementof claim 1 wherein said encapsulation layer includes an eatingcharacteristic which causes the presence of the encapsulation layer tobe substantially imperceptible to a person upon consumption of the bakedfood product.
 3. The improvement of claim 1 wherein said encapsulationlayer is formed of a protein encapsulated starch.
 4. The improvement ofclaim 1 wherein an outermost portion of said baked layer is formed intoa substantially de-aerated outer crust which substantially completelysurrounds the baked food product.
 5. The improvement of claim 1 whereinthe baked food product includes an overall outline which provides forre-heating in a standard upright toaster.
 6. The product of claim 5wherein said substantially de-aerated crust serves to preserve saidoverall outline of the baked food product during re-heating.
 7. Theproduct of claim 1 wherein said filling includes a water base.
 8. Theproduct of claim 1 wherein said filling includes a moisture content thatis greater 75%.
 9. The product of claim 1 wherein said filling includesa fatty base.
 10. In a method for producing a baked food productincluding a filling surrounded by a baked layer, the improvementcomprising the step of: forming an edible encapsulation layersubstantially surrounding said filling and disposed between the fillingand the baked layer to substantially maintain separation between thefilling and the surrounding baked layer at least to a limited extentduring initial baking and during subsequent storage and re-heating. 11.The improvement of claim 10 wherein said encapsulation layer includes aneating characteristic which causes the presence of the encapsulationlayer to be substantially imperceptible to a person upon consumption ofthe baked food product.
 12. A method for producing a baked food product,said method comprising the steps of: a) preparing a core pocket which ismade up of a filling surrounded by an encapsulant layer whichencapsulant layer is intended to prevent penetration of the filling intothe encapsulant layer and to prevent escape of the filling through theencapsulant layer; b) covering the core pocket with an outer layerhaving particular baked eating characteristics to form a pre-bakedproduct such that said outer layer surrounds said encapsulant layer; andc) baking the pre-baked product in a predetermined way to form saidbaked food product such that said encapsulant layer serves to maintainthe separation between the filling and said outer layer so as topreserve the baked eating characteristics of said outer layer and saidencapsulant layer includes an eating characteristic which causes thepresence of the encapsulant layer to be substantially imperceptible to aperson upon consumption of the baked food product with or withoutre-heating.
 13. The method of claim 12 wherein said baking step isperformed in said predetermined way using a pressure above ambientpressure.
 14. The method of claim 12 wherein said baking step isperformed in said predetermined way to cause an outermost portion ofsaid outer layer to form into a substantially de-aerated outer crustwhich substantially completely surrounds the baked food product suchthat the substantially de-aerated outer crust serves to preserve anoverall outline of the baked product during re-heating.
 15. The methodof claim 14 wherein said core pocket includes a configuration adaptedfor re-heating in an upright toaster and said outer layer is applied soas to cover the core portion such that the overall outline of the bakedfood product is suitable for re-heating in an upright toaster.
 16. Themethod of claim 12 wherein said step of preparing the core pocketincludes the steps of i) providing said filling, ii) sealing saidfilling inside said encapsulant layer, and iii) treating saidencapsulant layer with said filling sealed therein in a way whichenhances the ability of the encapsulant layer to maintain containment ofthe filling.
 17. The method of claim 16 wherein said encapsulant layeris formed from a protein encapsulated starch having an outermost proteinlayer and the step of treating the encapsulant layer includes the stepof par boiling the core pocket in water.
 18. The method of claim 16wherein said step of preparing the core pocket further comprises thestep of: iv) after said treating step, freezing the core portion forstorage prior to said baking step.
 19. The method of claim 12 whereinsaid step of preparing the core pocket includes the steps of: i)preparing a dough having a protein content, ii) forming said dough intosheet portions, each of which includes a thickness which issubstantially less than a width and length of the sheet portion suchthat the sheet portions include an outermost protein film which is madeup of a portion of said protein content, and iii) sealing said fillingwithin at least one of said sheet portions.
 20. The method of claim 19wherein said sheet portions are formed from said dough by sheetingaction.
 21. The method of claim 12 wherein said step of covering thecore pocket with said outer layer includes the steps of i) preparing abaking dough having said particular baked eating characteristics, ii)forming said baking dough into sheet portions, each of which includes athickness which is substantially less than a width and length of thesheet portion, and iii) surrounding said core portion with the bakingdough using at least one of said sheet portions.
 22. A baked foodproduct made in accordance with the method of claim
 12. 23. A method forproducing a baked comestible, said method comprising the steps of: a)preparing a baking mixture including at least one leavening agentprovided in a predetermined amount; and b) baking the baking mixture ina way which limits expansion of the baking mixture to establish a bakeddensity of the baked comestible and such that the predetermined amountof said leavening agent is sufficient to limit the time required forbaking the baked comestible.
 24. The method of claim 23 wherein saidpredetermined amount of leavening agent is substantially greater than aminimum amount of the leavening agent capable of producing said bakeddensity.
 25. The method of claim 24 wherein the predetermined amount ofsaid leavening agent is 40% or more greater than said minimum amount ofthe leavening agent.
 26. The method of claim 23 wherein said baking stepis performed by placing the baking mixture in a mold cavity defined byan interior wall of a mold arrangement and heating the mold arrangementin a way which causes pressure and temperature in the mold cavity torise above ambient levels so as to force a portion of the baking mixtureagainst the interior wall of the mold arrangement to form said portionof the baking mixture into an enhanced substantially de-aerated crustwhich surrounds a core portion of the baked product and wherein thepresence of said predetermined amount of leavening agent, greater thansaid minimum amount, contributes to the formation of the enhancedsubstantially de-aerated crust.
 27. The method of claim 23 wherein saidleavening agent includes an undesirable taste characteristic and whereinsaid predetermined amount of leavening agent is determined based on theleavening agent imparting said undesirable taste characteristic to thebaked comestible.
 28. A baked food product made in accordance with theprocess of claim
 23. 29. In a baked food product having a baked density,the improvement comprising: a leavening agent in a predetermined amountsufficiently uniformly distributed throughout at least a portion of thebaked food product such that the predetermined amount of said leaveningagent in a baking dough which is baked to form the baked food product issufficient to limit the time required for baking the baking dough in amold cavity defined by a mold arrangement where the mold arrangement isheated to cause pressure and temperature in the mold cavity containingthe baking dough to rise above ambient levels and such that thepredetermined amount of said leavening agent is substantially greaterthan a minimum amount of the leavening agent capable of producing saidbaked density.
 30. The improvement of claim 29 wherein the predeterminedamount of said leavening agent is 40% or more greater than said minimumamount of the leavening agent.
 31. The improvement of claim 29 whereinsaid leavening agent includes an undesirable taste characteristic andwherein said predetermined amount of leavening agent is determined basedon the leavening agent imparting said undesirable taste characteristicto the baked comestible.
 32. The improvement of claim 29 wherein themold cavity defines a baked outline and wherein the portion of saidpredetermined amount of leavening agent above said minimum amountcontributes pressure which forces a portion of the baking dough againstthe interior wall of the mold arrangement to form said portion of thebaking dough into an enhanced substantially de-aerated crust whichsurrounds a core portion of the baked food product whereby the enhancedsubstantially de-aerated crust is intended to substantially maintain thebaked outline of the baked food product when the product is re-heated.33. In a baked food product having a baked density and a baked outlineproduced using a mold arrangement having an interior wall defining amold cavity, the improvement comprising: a leavening agent in apredetermined amount sufficiently uniformly distributed throughout abaking mixture which forms the baked food product such that thepredetermined amount of said leavening agent in the baking mixture issubstantially greater than a minimum amount of the leavening agentcapable of producing said baked density for causing the baking mixtureto fill the mold cavity and the portion of leavening agent above saidminimum amount contributes pressure which forces a portion of the bakingmixture against the interior wall of the mold arrangement to form saidportion of the baking mixture into an enhanced substantially de-aeratedcrust which surrounds a core portion of the baked food product wherebythe enhanced substantially de-aerated crust serves to maintain the bakedoutline of the baked food product when the product is re-heated.
 34. Amethod for producing a filled baked food product using a moldarrangement having an interior surface defining a mold cavity, saidmethod comprising the steps of: a) preparing a baking mixture includingat least one leavening agent provided in a predetermined amount; b)preparing a core pocket which is made up of a filling surrounded by anencapsulant layer which encapsulant layer is intended to substantiallyprevent penetration of the filling into the encapsulant layer and tosubstantially prevent escape of the filling sealed therein; c) coveringthe core pocket with an outer layer of a baking mixture havingparticular baked eating characteristics to form a pre-baked product suchthat said outer layer of baking mixture surrounds said encapsulantlayer; d) sealing the pre-baked product in said mold cavity to limitexpansion of the pre-baked product and to establish a baked outline; ande) heating the mold arrangement such that pressure and temperature inthe mold cavity rise sufficiently to bake the pre-baked product in a waywhich establishes a baked density of the outer layer and thepredetermined amount of said leavening agent is sufficient to limit thetime required for baking the baked comestible and to contribute topressure build-up in the mold cavity which causes a portion of the outerlayer to be forced against said interior surface to form a portion ofsaid outer layer into an enhanced substantially de-aerated crust whilesaid encapsulant layer serves to maintain separation between the fillingand said outer layer to preserve the baked eating characteristics ofsaid outer layer and such that said encapsulant layer includes an eatingcharacteristic which causes the presence of the encapsulant layer to besubstantially imperceptible to a person upon subsequent consumption ofthe baked food product so that the enhanced substantially de-aeratedcrust serves to maintain the baked outline of the baked food product,even when re-heated from an unfrozen state, and the core pocket servesto maintain separation of the filling and the outer layer at least to alimited extent, even when re-heated from an unfrozen state.
 35. Anarrangement for use in producing a comestible from a baking mixture,said arrangement comprising: a) a molding arrangement which defines amold cavity using first and second mold members each of which includesan interior surface, which mold members are sealable against one anotherto isolate the mold cavity from ambient pressure to a predetermineddegree and which molding members are configured for receiving apredetermined portion of said baking mixture in the mold cavity; and b)a heating arrangement which heats the molding means with saidpredetermined portion of said baking mixture in the mold cavity suchthat pressure in the mold cavity, as determined by the predetermineddegree of seal between the first and second mold members, rises aboveambient pressure in a way which forces a portion of the baking mixtureagainst the interior wall of the mold arrangement to form said portionof the baking mixture into an enhanced substantially de-aerated crustwhich surrounds a core portion of the baked product.
 36. The arrangementof claim 35 wherein the predetermined degree of seal between the firstand second mold members is substantially attributable to the weight ofone of the mold members such that said de-aerated crust is formedwithout the need to lock the first and second mold members against oneanother so as to establish said predetermined degree of seal.